MEAN WELL NPB-1200 Series 1200W Intelligent Battery Charger

Product Overview

The MEAN WELL NPB-1200 series is a miniaturized, versatile, and ultra-wide voltage intelligent battery charger. It features a fully digital control design with automatic battery voltage detection, offering intelligent, user-friendly, safe, and compact operation. The series provides four models with output voltage ranges covering 10.5V to 80V, accommodating a wide variety of battery voltages and chemistries. It is designed for high reliability and offers excellent cost performance.

Key features include built-in CANBus protocol for control and monitoring, programmable charging curves via the SBP-001 programmer, manual setting for 2/3 stage charging and 4 built-in curves via DIP S.W, and multiple protections such as short circuit, over voltage, over temperature, battery under voltage, and reverse polarity. It operates across a wide temperature range of -30°C to +70°C and is dual-certified to ITE IEC/EN/UL62368-1 and household appliance EN60335-1/-2-29 standards, backed by a 3-year warranty.

Key Features

• Auto ranging with ultra-wide charging voltage (10.5V~21V, 21V~42V, 42V~80V).
• Built-in CANBus protocol for control, setting, and monitoring.
• Programmable charging curve via SBP-001 programmer.
• Manual setting for 2/3 stage and 4 built-in charging curves via DIP S.W.
• Multiple protections: Short circuit, Over voltage, Over temperature, Battery under voltage, Battery reverse polarity (no damage).
• Temperature compensation function to prolong battery life (Lead-acid only).
• Wide operating temperature range: -30°C to +70°C.
• Thermal controlled DC fan for noise reduction.
• Remote ON/OFF control.
• Comply with 62368-1 + 60335-1/-2-29 dual certification.
• Suitable for lead-acid (Pb) and li-ion batteries.
• 3 years warranty.

Applications

• AGV (Automated Guided Vehicle)
• E-Bike, E-Scooter, Camping car, Bus, Specialty vehicles
• Robotic lawn mower, Washing robot
• Recreation craft, Personal yacht or workboat
• Surveillance system
• Telecommunication base station
• Radio system backup solution
• Equipments or instruments with back-up battery

Technical Specifications

For a complete list of specifications, please refer to the detailed tables in the original document.

Functionality and Operation

Manual Setting

The charger offers manual configuration options via DIP switches on the panel:

• 2 or 3-Stage Selectable: DIP SW 1 controls the charging stage selection (Default: 3-stage, ON: 2-stage).
• Charging Curve Adjustment: DIP SW 2 and 3 allow selection from 4 built-in charging curves suitable for different battery types (e.g., Gel, Flooded, AGM, LiFe04).

Charging Curve Profiles: The charger supports 2-stage (Constant Current, Constant Voltage) and 3-stage (Constant Current, Constant Voltage, Float) charging profiles. Specific voltage and current settings for each stage and battery type are detailed in the specification tables.

Programmable Charging Curve

The SBP-001 programmer (sold separately) allows for advanced configuration of charging parameters such as constant current (CC), taper current (TC), constant voltage (CV), float voltage (FV), and charging timeout. This enables customization for specific battery requirements.

Configuration Process: Involves hardware setup (DIP SW settings, jumper removal) and connecting the SBP-001 programmer to the NPB-1200 and a personal computer via a communication cable. Software on the PC is used to set parameters.

Auto Ranging for Charging

The NPB-1200 features an auto-ranging mode, primarily intended for lithium batteries with a Battery Management System (BMS). When enabled, the charger automatically detects the connected battery voltage and adjusts the charging voltage accordingly. This mode is factory-set to OFF and can be enabled via specific DIP SW settings. It is prohibited for non-lithium batteries.

Enabling Auto-Ranging: Requires setting DIP SWs to OFF, applying AC power, then cycling all DIP SWs to ON and back to OFF within 15 seconds. A green LED flashing 3 times confirms successful setup. The unit must then be restarted. The jumper on pins 7 & 8 should be in place.

Disabling Auto-Ranging: Involves setting all DIP switches to ON, applying AC power, then cycling all DIP switches from ON to OFF and back to ON within 15 seconds. A green LED flashing 3 times indicates success.

Auto Derating Function

The charger incorporates an auto-derating function to protect against over-temperature conditions. When the internal temperature reaches a threshold (e.g., 95°C), the output current is automatically reduced to maintain operation without triggering an immediate shutdown. This function is active during charging or when controlled via CANBus.

Derating Curves: Illustrate how output power or current is affected by ambient temperature and input voltage. For instance, output current is reduced as ambient temperature increases beyond a certain point (T1).

CANBus Communication Interface

The NPB-1200 supports CANBus 2.0B, enabling comprehensive control, setting, and monitoring capabilities. Users can manage output voltage, output current, internal temperature, and DC output ON/OFF remotely. A detailed list of CANBus commands is provided for various functions, including reading status, setting parameters, and retrieving manufacturer information.

Signal and Indicator Functions

• Charger OK Signal: A TTL level signal (4.5~5.5V for 'High', -0.5~0.5V for 'Low') indicating normal operation or failure/protection status.
• Battery Full Signal: A TTL level signal (4.5~5.5V for 'High', -0.5~0.5V for 'Low') indicating battery full status or charging status.
• Remote ON/OFF Control: The unit can be turned ON/OFF via a dry contact connected to the Remote ON-OFF (pin 7) and +12Vaux (pin 8) terminals. A short circuit turns it ON (default), while an open circuit turns it OFF.
• Temperature Compensation: For 3-stage charging, an optional NTC sensor can be connected to compensate charging voltage based on battery temperature (0~40°C range).
• DC Output LED Indicators:
  • Green LED: Indicates Float (stage 3) or Battery Full.
  • Orange LED: Indicates Charging (stage 1 or stage 2).
  • Flashing Orange LED: Indicates Auto-ranging for charging.
  • Red LED: Indicates Abnormal status (e.g., OTP, OVP, short circuit, reverse polarity, charging timeout).
  • Flashing Red LED: Indicates the unit is overheated internally (above 95°C), operating normally but signaling an alarm via CANBus.

Mechanical Specifications

The NPB-1200 series features a compact design with specific dimensions (250mm x 158mm x 67mm) and considerations for airflow direction. The unit is equipped with connectors for control and communication.

DIP Switch and LED Status: The DIP switches are used for selecting charging stages (2 or 3) and pre-defined charging curves. The LED status table summarizes the meaning of the Green, Orange, and Red indicators.

Connector Pin Assignments: Detailed pinouts are provided for the 14-pin connector on the NPB-1200 (including signals like CANBus, Charger OK, Battery Full, Remote ON/OFF, +12Vaux, NTC sensors) and the 10-pin connector on the SBP-001 programmer.

Accessories: Standard accessories include an NTC sensor wire and a remote control mating wire. An optional carry handle kit is available separately, comprising a handle, foot pads, and screws.

Block Diagram: Illustrates the internal architecture, showing the flow from AC input through EMI filtering, inrush current limiting, PFC, power switching, rectification, and filtering to the DC output. Key control and protection circuits like OVP, OTP, reverse detection, MCU, and CANBus interface are integrated.

Derating Curves: Visual representations showing how output power is affected by ambient temperature, how load capacity varies with input voltage, and how output current is adjusted based on charging voltage for different models.

Installation Manual

For detailed installation procedures, please refer to the official installation manual available at: http://www.meanwell.com/manual.html